Autonomous device for in-field conversion of biomass into biochar

ABSTRACT

Systems, methods and apparatus for the thermal conversion of biomass into biochar. A mobile platform may be used to maneuver a mobile biochar generation system within a field of biomass. The biomass may be harvested, preprocessed and pyrolyzed. After pyrolyzation, the biochar may be cooled to a predetermined temperature by integrating water and liquid nutrients into the biochar. The system may then control the application of the infused biochar by adjusting a spreading attachment and a plowing attachment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of and claims priority to U.S. patentapplication Ser. No. 17/353,770, filed 21 Jun. 2021, and titled“AUTONOMOUS DEVICE FOR IN-FIELD CONVERSION OF BIOMASS INTO BIOCHAR,”which in turn claims the benefit of U.S. Provisional Application No.63/041,702, filed 19 Jun. 2020, and U.S. Provisional Application No.63/091,263, filed 13 Oct. 2020, all of which are hereby incorporated byreference in their entireties.

FIELD OF INVENTION

This subject invention relates to robots, preferably an autonomous robotfor thermal conversion of biomass into biochar.

BACKGROUND

The thermal conversion of biomass into charcoal or biochar is known aspyrolysis. During pyrolysis, biomass feedstock is heated to temperaturesin excess of 300 degrees centigrade under restricted oxygen conditions,resulting in the thermal decomposition of the biomass. Pyrolysis ofbiomass generates flammable, gaseous byproducts (pyrolysis gas), liquidbyproducts (pyrolysis oils) and solid products (biochar). The ratio ofeach product is determined by the temperature and oxygen concentrationof the pyrolysis oven, and the amount of time the biomass feedstock isexposed to pyrolysis conditions (residence time).

Production of biochar is of particular interest to agriculture due to anumber of beneficial soil amendment properties. When added to soil,biochar increases carbon concentration, which results in improved waterholding capacity, nutrient retention and aeration. Biochar also impactsthe chemical composition of the soil by increasing soil pH, andincreasing cation exchange capacity. Changes in soil properties as aresult of biochar application may increase crop yield and/or reduceinput requirements (fertilizer, water etc.).

Biochar is also interesting as a means to sequester atmospheric carbonand reduce the impact of global climate change. When waste biomass isthermally converted to biochar, a significant portion of the carboncontent of the feedstock is converted to a mineral form of carbon. Inits mineral form, carbon is not readily decomposed. When this mineralcarbon is added to soils, it can be safely sequestered for many years.It is estimated that one tonne of biochar is equivalent to more than 3tons of carbon-dioxide equivalent, based on the molecular weight ofcarbon dioxide. Large-scale production of biochar from agriculturalwaste biomass has the potential to sequester vast amounts of atmosphericCO2.

A key challenge associated with scaling up biochar production globallyis the availability of biomass waste feedstock in sufficient quantities,and the costs associated with collecting these feedstocks for thermalconversion. Similarly, another challenge is the cost of redistributingthe biochar to the soil across many acres of farmland. Finally, the highcost of building a large, centralized, biochar plant is oftenprohibitive to rapid growth of producers.

SUMMARY

Described herein is an exemplary system and methods of operation anautonomous robot for thermal conversion of biomass into biochar.

In some embodiments, the system may be configured to control a mobilebiochar generation system. In some embodiments, an optimal path of atractor or other transportation unit may be determined. The system mayinclude a harvesting unit, wherein the harvesting unit may be a forageharvester mounted on a tractor. The harvesting unit may be mounted infront of the tractor or between the tractor and a trailer unit whichhouses a pyrolytic system.

In some embodiments, there may be a plurality of sensor arrays mountedon and inside different components of the system. The plurality ofsensor arrays may be used to track and characterize properties ofbiomass, biochar, exhaust gas and infused biochar.

In some embodiments, biomass may be transferred into a pyrolytic reactorwith a pyrolyzing auger. The pyrolytic reactor may comprise a thermallyinsulated enclosure, one or more heat source, including induction andresistance based heating sources, a portion of the pyrolytic auger andinjection ports for gas injection. In some embodiments, the pyrolyticauger may have a hollow shaft with holes along its length where gas andsteam may be injected into the reactor.

The pyrolytic reactor may pyrolyze the harvested biomass and generatebiochar and exhaust gas. In some embodiments, postprocessing may beperformed on the biochar. Post processing may include cooling in aquenching auger, spraying with water, integration of liquid nutrientsinto the biochar or combination thereof.

In some embodiments, a biochar handling unit may be configured to applythe infused biochar in into a soil region. The biochar handling unit maycomprise a spreader unit and a plowing unit to evenly integrate thebiochar into the soil.

In some embodiments, the location, amount and density of biocharapplication may be mapped, saved and analyzed.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description, the claims and the drawings. Thedetailed description and specific examples are intended for illustrationonly and are not intended to limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become better understood from the detaileddescription and the drawings, wherein:

FIG. 1 illustrates an example embodiment of a pyrolysis system inaccordance with aspects of the present disclosure.

FIG. 2 illustrates an example embodiment of the pyrolysis system inaccordance with aspects of the present disclosure.

FIG. 3 illustrates an example embodiment of a robotic mobility system inaccordance with aspects of the present disclosure.

FIG. 4 illustrates an example embodiment of the robotic mobility systemin accordance with aspects of the present disclosure.

FIG. 5 illustrates an example embodiment of the robotic mobility systemin accordance with aspects of the present disclosure.

FIG. 6 illustrates an example embodiment of a metal housing for thepyrolysis system in accordance with aspects of the present disclosure.

FIG. 7 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 8 illustrates an example embodiment of a controller subsystem inaccordance with aspects of the present disclosure.

FIG. 9 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 10 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 11 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 12 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 13 illustrates an example flowchart of a process performed by thesystem in accordance with aspects of the present disclosure.

FIG. 14 illustrates an example of a fleet of robots operating in asynchronized fashion in accordance with aspects of the presentdisclosure.

FIG. 15 illustrates an example embodiment of the complete system with anautonomous lead vehicle in accordance with aspects of the presentdisclosure.

FIG. 16 illustrates an example embodiment of the complete system with anautonomous lead vehicle in accordance with aspects of the presentdisclosure.

FIG. 17 illustrates an example of the biochar production system andpyrolysis reactor in accordance with aspects of the present disclosure.

FIG. 18 illustrates an example of the biochar production system andpyrolysis reactor in accordance with aspects of the present disclosure.

FIG. 19 illustrates an example of a stationary biochar production systemand pyrolysis reactor heated by induction heating elements in accordancewith aspects of the present disclosure.

FIG. 20 illustrates an example of a stationary biochar production systemand pyrolysis reactor heated by induction heating elements in accordancewith aspects of the present disclosure.

FIG. 21A illustrates an example of the biochar production system andpyrolysis reactor in accordance with aspects of the present disclosure.

FIG. 21B illustrates an example of a pyrolytic auger in accordance withaspects of the present disclosure.

FIG. 21C illustrates an example of a pyrolytic auger in accordance withaspects of the present disclosure.

FIG. 21D illustrates an example of a pyrolytic auger in accordance withaspects of the present disclosure.

FIG. 21E illustrates an example of a pyrolytic auger with a hollow shaftin accordance with aspects of the present disclosure.

FIG. 21F illustrates an example of a pyrolytic auger with a hollow shaftin accordance with aspects of the present disclosure.

FIG. 22A illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22B illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22C illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22D illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22E illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22F illustrates an example of a towable biochar production systemand pyrolysis reactor in accordance with aspects of the presentdisclosure.

FIG. 22G illustrates an example of a thermally insulated enclosure of apyrolytic auger and pyrolysis system in accordance with aspects of thepresent disclosure.

FIG. 22H illustrates an example of a cooling system with a quenchingauger in accordance with aspects of the present disclosure.

FIG. 22I illustrates an example of a biochar production system andpyrolysis reactor being towed by a tractor with an attached frontalforage harvester in accordance with aspects of the present disclosure

FIG. 23 illustrates an example of a mobile biochar generation system inaccordance with aspects of the present disclosure.

FIG. 24A illustrates an example of a biochar generation systemcontroller in accordance with aspects of the present disclosure.

FIG. 24B illustrates an example of a sensor array controller inaccordance with aspects of the present disclosure.

FIG. 25 is a diagram illustrating an exemplary computer that may performprocessing in some embodiments and in accordance with aspects of thepresent disclosure.

FIG. 26A is a flow chart illustrating an exemplary method that may beperformed in accordance with some embodiments.

FIG. 26B is a flow chart illustrating an exemplary method that may beperformed in accordance with some embodiments.

DETAILED DESCRIPTION

In this specification, reference is made in detail to specificembodiments of the invention. Some of the embodiments or their aspectsare illustrated in the drawings.

For clarity in explanation, the invention has been described withreference to specific embodiments, however it should be understood thatthe invention is not limited to the described embodiments. On thecontrary, the invention covers alternatives, modifications, andequivalents as may be included within its scope as defined by any patentclaims. The following embodiments of the invention are set forth withoutany loss of generality to, and without imposing limitations on, theclaimed invention. In the following description, specific details areset forth in order to provide a thorough understanding of the presentinvention. The present invention may be practiced without some or all ofthese specific details. In addition, well known features may not havebeen described in detail to avoid unnecessarily obscuring the invention.

In addition, it should be understood that steps of the exemplary methodsset forth in this exemplary patent can be performed in different ordersthan the order presented in this specification. Furthermore, some stepsof the exemplary methods may be performed in parallel rather than beingperformed sequentially. Also, the steps of the exemplary methods may beperformed in a network environment in which some steps are performed bydifferent computers in the networked environment.

Some embodiments are implemented by a computer system. A computer systemmay include a processor, a memory, and a non-transitorycomputer-readable medium. The memory and non-transitory medium may storeinstructions for performing methods and steps described herein.

Aside from the preferred embodiment or embodiments disclosed below, thisinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Thus, it is to be understood that theinvention is not limited in its application to the details ofconstruction and the arrangements of components set forth in thefollowing description or illustrated in the drawings. If only oneembodiment is described herein, the claims hereof are not to be limitedto that embodiment. Moreover, the claims hereof are not to be readrestrictively unless there is clear and convincing evidence manifestinga certain exclusion, restriction, or disclaimer.

Disclosed is a mobile robot-based system that converts biomass feedstockinto biochar in the field. Unlike centralized biochar production plants,the robot drives across open land or farm fields and converts drybiomass on the soil surface directly into biochar in the field. Therobot preferably includes an outdoor mobility platform, a power source,sensors able to detect the boundary of the robot's designated operatingarea, sensors able to detect obstacles, one or more sensors that candetect the presence and type of biomass, and a mechanism for convertingthe biomass into biochar. Optionally included are a system forcollecting information about soil and plants, and a system forcollecting images of plants and soil as well as data for offlineanalysis of plant/soil health and/or visualization of growth over time.

The mobility platform may include four or six drive wheels each poweredby an independent motor controlled by a common microprocessor. In someembodiments, the mobility platform may be a tractor. The tractor may beautonomous, semi-autonomous with human supervision or human operated.The robot is powered by an internal battery which can be chargedelectrically or via an onboard solar panel. The robot may also bepowered by a fuel cell. The robot uses GPS and other sensors todetermine its absolute position and its position relative to theboundary of the field in which the robot can travel. GPS and othersensors may also be used as a means to geolocate sequestered biocharcarbon for accounting, auditing, and monetization of carbon credits andtheir derivatives.

The robot uses a number of onboard sensors to identify and avoidobstacles. These sensors include ultrasonic sensors, Lidar, radar, andcameras. The robot may also utilize touch or capacitive sensors alongits perimeter to identify obstacles.

The robot uses a number of onboard sensors to navigate within itsenvironment and determine an optimal path. These sensors include lidar,radar, gps, cameras and ultrasonic sensors.

The biomass pyrolysis system includes a heat source capable of reachingtemperatures in excess of 250 degrees centigrade. This heat source couldbe an electric heater, a ceramic heater, a laser, a microwave energysource, infrared heater or a burner capable of combusting a liquid orgaseous fuel such as propane. The biomass pyrolysis system also consistsof a thermally-insulated metal or ceramic enclosure that allows biomassto enter and exit but restricts the entry of oxygen. This enclosure mayinclude curtains or flaps to restrict oxygen within the pyrolysischamber while allowing biomass to freely enter and exit. An onboardsystem to consolidate, reorient, or compartmentalize field collectedbiomass within the robot may be used to optimize thermal conversionefficiencies. The Pyrolysis system may also include a chimney forexhaust of gases and combustion products, along with a blower or sourceof pressurized inert gas to control the amount of oxygen present in thepyrolysis chamber. The pyrolysis system also includes a temperaturecontroller which regulates the intensity of the heat source to achieveand maintain a desired temperature.

The pyrolysis system includes a number of sensors to monitor andoptimize the pyrolysis process. These sensors may include temperaturesensors, sensors to measure the concentration of gases such as oxygenand carbon dioxide and sensors to measure the speed of the robot todetermine biomass residence time.

The pyrolysis system may include a number of actuators to optimize thepyrolysis process including electrically operated augers or wheels toefficiently move biomass through the pyrolysis zone. The pyrolysissystem may also include actuators to adjust the height of the enclosure.

The pyrolysis system may include active and passive cooling systems toreduce the temperature of the biochar below combustion temperature.These cooling systems may include blowers, water sprayers, heat sinks,refrigeration systems or peltier coolers to reduce the temperature ofthe biochar. The cooling system may integrate nutrient laden fluidscontaining nitrogen, phosphorous, potassium, calcium, magnesium, sulfur,iron, manganese, copper, zinc, boron, molybdenum, or other derivativesto facilitate plant growth and/or balance soil pH.

The pyrolysis system may be mounted on two or more wheels and towed bythe mobility platform. The pyrolysis system may also be physicallymounted onto the robotic mobility system itself.

The robot includes a wireless communication system for bidirectionaltransmission of control and telemetry data to the cloud or to a humanoperator. The robot also includes a mesh wireless communication systemfor bidirectional transmission of control and telemetry data to otherrobots in the same area. The robot may communicate via establishedwireless standards including, wife, Bluetooth, sub gigahertz technology,LoRaWan, Satellite or cellular data connections.

Key abilities of the preferred robot include the ability to operatewithout supervision, the ability to be controlled by a remote operator,the ability to convert biomass into biochar, and the ability tothermally eliminate weeds. In some embodiments, the robot may be thesize of a full size tractor. In some embodiments, the robot may be ofsmall size, allowing operation in narrow rows and reducing oreliminating soil compaction because of its low weight.

The robot uses onboard sensors to identify and characterize the type,temperature, moisture content and composition of incoming biomassfeedstock. Sensors are also used to identify the temperature andcomposition of exiting biochar. These sensors may include temperaturesensors, thermal imaging systems, cameras, multispectral imaging systemsor hyperspectral imaging systems. Such sensors shall also be used toidentify open flames in proximity to the robot and automaticallyactivate onboard fire suppression measures including dispersion of firesquelching agents including water, wetting agents, foam, dry chemicals,or dry powders.

In order to program the robot's path and navigation, a user first entersthe GPS coordinates of the boundaries of the field of operation. Thisdata can be entered via a PC, smartphone, tablet or a human machineinterface (hmi) on the robot itself. The user can then program a desiredpath of operation or allow the robot to determine the optimal path ofoperation. The operator can also control the robot directly via a remotecontrol. A human operator can also manually input the desiredtemperature, oxygen concentration and residence time for the pyrolysisoven.

The robot navigates to its starting point and begins its process ofnavigation and path planning. Using its onboard sensors, the robotidentifies features in its surroundings including but not limited to theshape and presence of rows. The robot may utilize its onboard camerasand a computer vision algorithm to identify the presence of rows. Therobot also utilizes its onboard sensors to identify the presence of anyobstacles that may impede its movement. The robot also uses its onboardsensors to identify any regions of high moisture content that mightimpede travel.

The robot uses a combination of its onboard sensors, GPS andnavigational algorithms to determine an optimal path that covers thedesired area while avoiding obstacles.

As the robot navigates its path, in addition to scanning for obstacles,it continuously monitors and characterizes the incoming biomass. Usingsensors such as cameras, temperature sensors, thermal imaging systems,lidar and soil moisture sensors the robot captures and stores data aboutthe incoming biomass. Using a combination of onboard algorithms,computer vision and data analysis techniques the robot determines thetemperature, moisture content and chemical composition of the incomingbiomass.

Using an internal algorithm, the robot continuously adjusts thetemperature of the heat source, oxygen concentration of the pyrolysissystem and the intensity of the blower or inert gas source to optimizepyrolysis. The robot also optimizes and adjusts the residence time ofbiomass in the pyrolysis chamber by changing its speed of travel. Thesepyrolysis process parameters can be adjusted to produce the desiredamounts of biochar, pyrolysis gas and/or pyrolysis oil. These parameterscan also be manipulated to produce a biochar with particular propertiesas determined by the user (full or incomplete carbonization). The robotcan also adjust these process parameters to reduce emissions of gaseousmaterial through the flue.

The robot uses a combination of onboard sensors including but notlimited to cameras, temperature sensors, thermal imaging systems, andhyper/multi spectral imaging systems to monitor and characterize thebiochar that is produced. The robot uses these sensors and an onboardcomputer vision algorithm to determine the temperature, composition,carbon content and moisture content of the biochar. Using data fromthese sensors, the robot then determines and applies an appropriate postprocessing treatment to the biochar.

Post-processing treatments may include cooling the biochar to a desiredtemperature, infusing it with nutrients or other soil amendments, orusing a tilling or scouring attachment to incorporate the biochar intothe soil. In order to cool the biochar, the robot may spray water, applyfire retardant or use a blower to reduce the temperature of the biochar.The robot may also use passive cooling system such as heat sinks,peltier coolers or refrigerators to reduce the temperature of thebiochar.

The robot may inject or spray the biochar with soil amendment or othertreatments such as fertilizer, compost, compost tea, nitrogen,pesticide, fungicide, herbicide and other additives to provideadditional agricultural or soil amendment benefits.

The robot may also utilize a tilling attachment to aerate the soil andto incorporate the biochar into the soil.

The robot utilizes a combination of onboard sensors including cameras,lidar and ultrasonic sensors to measure the height of the incomingbiomass. These data are processed by an internal algorithm. Based on theresults of the algorithm, the robot can adjust the height of thepyrolysis system via actuators and lifts to accommodate the size of theincoming biomass.

As the robot navigates its environment, its onboard sensors captureenvironmental data (temperature, moisture, humidity) soil data(moisture, color, temperature, electrical conductivity) and images ofthe surrounding vegetation. These data can be stored internally andtransmitted to the cloud for further analysis. These data can be used bythe robot to infer and characterize plant health, plant size, plantgrowth and plant type of the surrounding vegetation. These data can alsobe used by the robot to infer the health and chemical composition of thesoil, and the concentration of soil carbon. These data can be used totrack the growth of plants over time. These data can also be used totrack and monitor the carbon content of the soil.

If the robot encounters an obstacle, or detects that its movement isimpeded using onboard GPS, positional and inertial sensors, the robotcan attempt to navigate around the obstacle. If the robot is unable tonavigate around the obstacle, it can safely shut down the pyrolysissystem and alert a human operator.

When the robot reaches the end of a row, or a field boundary asdetermined by its GPS or user input, the robot will attempt to turnitself 180 degrees and proceed down the next row. In the event the robotcannot turn itself, it can safely shut down the pyrolysis system andalert a human operator.

The robot maintains an onboard fire detection system consisting ofsensors including temperature sensors, thermal imaging systems, andcameras. If the robot detects fire or flame outside the pyrolysis systemit can safely shut down the pyrolysis system and alert a human operator.

The robot includes an onboard fire suppression system consisting of asprayer capable of spraying water or fire retardant around the robot.The robot can maintain an onboard tank of water or fire retardant, orconnect to a remote tank via a hose. The robot may also with a dedicatedfire suppression robot to coordinate automated fire control. If the firesuppression system is activated, the robot can safely shut off thepyrolysis system and alert a human operator.

The robot may include physical pretreatment attachments to treat andprepare the biomass feedstock for pyrolysis. These pretreatmentattachments may include a spinning string or blade to cut or trim thebiomass. These attachments may also include a mowing system to cut,mulch or reduce the size of the biomass before pyrolysis. In someembodiments, the pretreatment attachment may be a front mounted forageharvester or combine. The robot may also include a heat source to dry orpreheat the biomass before pyrolysis.

While the primary purpose of the robot is to produce biochar, it mayalso be used to identify and thermally destroy weeds or other invasiveplant species. Using its onboard sensors, cameras and computer visionalgorithms, the robot can identify and characterize weeds or otherinvasive or undesired plants. The robot can then adjust the temperatureof the heat source for the pyrolysis system to thermally destroy theseplants. The system may include an actuator to physically position theheat source directly above the weed to minimize its impact onsurrounding plants.

The robot can operate alone or in concert with other robots. Whenoperated in concert with other robots, the user can set the desired pathand boundaries via a fleet management platform. This fleet managementplatform can also be used to schedule and coordinate the activities ofthe robots.

The robot is powered by an onboard, rechargeable battery. This batterypowers the mobility system, sensors, actuators and microcontrollers. Thebattery can also power the heat source. The battery can be chargedelectrically or through an onboard array of solar panels and solarcharge controller. The battery can also be charged via an onboardgasoline, propane or diesel generator or a fuel cell. The robot can alsocarry an onboard fuel tank such as propane or natural gas to providefuel for a burner as a heat source and power a generator. In someembodiments, the robot may be powered mechanically, either directly orpartially from an internal combustion engine. The internal combustionengine may be a diesel engine, gasoline engine or mixed gas engine. Insome embodiments, liquid natural gas, propane, kerosene, syngas,hydrogen gas, gasoline, diesel or combination thereof may be used as thefuel source.

The robot can be programmed to navigate and return to a particulargeographic location when its battery charge is low. The robot can thenconnect to a charging station to recharge its internal battery. Once theinternal battery is charged, the robot can resume its normal operations.

FIG. 1 shows an example of the pyrolysis system. A thermally-insulatedmetal housing 1 is mounted underneath the system to reduce the ingressof oxygen. A blower 2 is used to control the amount of oxygen present inthe pyrolysis chamber. A flue 3 is installed to safely vent pyrolysisgases. A sensor array 4 is used to monitor the temperature andcomposition of the pyrolysis gas. A microcontroller 5 is used to controland optimize process parameters. A generator 6 is used to power therobot and heat source. A suite of sensors 7 is used to monitor and trackpyrolysis parameters.

FIG. 2 shows the pyrolysis system 8 traveling along a field of drybiomass 9. The converted biochar 10 is shown exiting the pyrolysischamber at high temperature as the system moves forward.

FIG. 3 shows a robotic mobility system 11 with four drive wheels 12 anda suite of onboard sensors 13. The pyrolysis system 14 is towed behindthe robotic mobility system and connected by a coupling 15.

FIG. 4 shows a robotic mobility system 16 pulling the pyrolysis system17 across a row of biomass feedstock 18. The resultant biochar 19 isshown to exit the pyrolysis system as the robot moves forward.

FIG. 5 shows the underside of the robotic mobility system 20 with anarray of sensors 21 towing the pyrolysis system 22 with insulated walls23. The heat source 24 and flue 25 are visible.

FIG. 6 shows the insulated metal housing of the pyrolysis system 26which may be open on one or more sides to allow biomass to enter andexit or partially sealed with a curtain 27 or series of metal louvers.

FIG. 7 is a flow chart depicting the primary steps associated with anexemplary method of the invention and also describing an example of theprimary programming logic of the controller subsystem of a robot.

As shown in FIG. 7 , when the controller subsystem receives a signalfrom the biomass sensor(s), step 28, the controller subsystem activatesthe biomass pyrolysis system, step 29, and may control the drive wheelmotors to drive the robot forward, step 30, over the biomass, convertingit to biochar. After a predetermined distance traveled and/or after apredetermined time of travel, the controller subsystem de-activates thepyrolysis system, step 31. In other embodiments, the robot is notmaneuvered forward in order to convert the biomass to biochar. Then, thebiomass pyrolysis system is not activated.

As shown in step 32-34, if the controller subsystem receives a signalfrom the obstacle sensor, the controller subsystem controls the drivewheel motors to turn and steer away from the crop/obstacle. The biomasspyrolysis system is not activated. In other designs, microcontrollers,application specific integrated circuitry, or the like are used. Thecontroller subsystem preferably includes computer instructions stored inan on-board memory executed by a processor or processors. The computerinstructions are designed and coded per the flow chart of FIG. 7 and theexplanation herein.

FIG. 8 shows controller subsystem 35 controlling drive motors 36 andbiomass pyrolysis system 37 based on inputs from the biomass sensor(s)38, the obstacle sensor(s) 39 and navigation system 40. FIG. 8 alsoshows power management controller 41. Further included may be one ormore environmental sensors 42, an imager such as a camera 43, an imagecapture system 44, and a wireless communications subsystem (e.g.,Bluetooth, cellular, or Wi-Fi), 45. FIG. 7 also shows charge andprogramming port 46.

FIG. 9 shows a flow chart depicting the primary steps associated with anexemplary method of the invention and also describing an example of theprimary programming logic of the controller subsystem of a robot.

As shown in FIG. 9 , when the controller subsystem receives a signalfrom the biomass sensor(s), step 47, the controller subsystem activatesthe biomass pyrolysis system, step 48, and then measures the moisturecontent of the incoming biomass using a suite of sensors, step 49. Ifthe moisture content of the biomass is at or below a set threshold, thepyrolysis system is deactivated, step 50, and the robot maneuversforward. If the moisture content of the biomass feedstock is detected tobe below a set threshold, the temperature of the pyrolysis system isincreased, step 51, and subsequently deactivated, step 52. The robotthen maneuvers forward.

As shown in FIG. 10 , when the controller subsystem receives a signalfrom the biochar sensor(s), step 53, the controller subsystem activatesthe biochar temperature sensor and then measures the temperature of theexiting biochar using a suite of sensors, step 54. If the temperature ofthe biochar is at or below a set threshold, the biochar cooling systemis deactivated, step 55, and the robot maneuvers forward. If thetemperature of the biochar is detected to be above a set threshold, thebiochar cooling system is activated, step 56, and the robot thenmaneuvers forward.

As shown in FIG. 11 , when the controller subsystem receives a signalfrom the biochar sensor(s), step 57, the controller subsystem activatesthe biochar characterization system and then measures the carbon contentof the exiting biochar using a suite of sensors, step 58. If the carboncontent of the biochar is at or below a set threshold, the speed of thedrive wheels is decreased, step 59, and the robot maneuvers forward. Ifthe carbon content of the biochar is detected to be above a setthreshold, the speed of the drive wheels is increased, step 60, and therobot then maneuvers forward.

As shown in FIG. 12 , when the controller subsystem receives a signalfrom the biomass sensor(s), step 61, the controller subsystem activatesthe soil characterization system and then measures the carbon contentand other chemical and physical properties of the soil using a suite ofsensors, step 62. If the carbon content of the soil is at or below a setthreshold, the pyrolysis system is activated, step 63, and the robotmaneuvers forward. If the carbon content of the soil is detected to beabove a set threshold, the pyrolysis system is deactivated, step 64, andthe robot then maneuvers forward.

As shown in FIG. 13 , when the controller subsystem receives a signalfrom the weed sensor(s) indicating the presence and location of a weedor other invasive plant species, step 65, the controller subsystemactivates the pyrolysis system, step 66, and then sets the pyrolysissystem temperature to a maximum threshold, step 67. The robot then usesan actuator to adjust the position of the pyrolysis system heat sourceto be in close physical proximity to the weed, step 68, to thermallydestroy the weed. The robot then deactivates the pyrolysis system, step69, and moves forward.

As shown in FIG. 14 , a fleet of automated pyrolysis robots, step 71,are dispatched to a plot of land. The robots position, heading and speedis monitored, synchronized and controlled by a centralized fleetmanagement platform, step 72. The robots collect and process rawbiomass, step 73, and thermally convert it to biochar, step 74. Theresultant biochar is then dispensed onto the soil surface, step 75, ortilled into the topsoil using an onboard tiller, step 76, or collectedand bagged using an on-board bagging system, step 77.

As shown in FIG. 15 , the system is driven by a lead vehicle, step 78,which may consist of an autonomous robotics platform, a tractor, anall-terrain vehicle or a light electric vehicle. Sensors, lidar andcameras on board the lead vehicle capture information about theenvironment, and biomass ahead of the vehicle, step 79. Data collectedmay include the biomass moisture content, size, mass, color and type.Biomass is collected and processed to a predetermined size and bulkdensity using a modular biomass processing system, step 80, based ondata collected by sensors on the lead vehicle. Biomass is then conveyedto a hopper for temporary storage and, if necessary, further drying,step 81. Based on data collected from onboard sensors, the biomass inthe hopper is dried and further processed to a predetermined moisturelevel, step 82. Once dried, biomass is loaded into the biocharprocessing system, step 83. The temperature and residence time of thebiochar processing system is determined by the system's onboard computerand data collected from sensors, step 84. The resultant biochar iscooled to a predetermined temperature using a combination of heat sinks,fans and irrigation with water from an onboard or remote reservoir, step85. Additives including but not limited to chemical or organicfertilizer may then be added to the biochar from an onboard or remotereservoir, step 86. The resultant biochar, including any additives, isthen measured using an array of onboard sensors and cameras, step 87.Measurements may include mass, temperature, carbon content, cationexchange capacity, nitrogen content, phosphorous content, pH, color,texture, density and particle size. The biochar is then tagged with aGPS coordinate and dispensed onto the soil surface, or tilled into thetopsoil, or bagged for future use, step 88. The system is powered viaonboard batteries, which are charged using an onboard generator poweredby a combustible fuel or onboard or remote solar panels, step 89.

As shown in FIG. 16 , the robot and lead vehicle include a number ofonboard sensors such as RGB cameras, depth cameras, LiDAR, inertialmeasurement units, GPS, temperature, humidity, environmental sensors,radar and ultrasound, step 90. The robot and lead vehicle also have anarray of wireless communication equipment including cellular, wifi andsatellite connectivity, step 91. The lead vehicle is attached to therobot via a tow hitch, step 92. Biomass is collected and processed usinga modular biomass processing system, step 93. The modular biomassprocessing system 93 may be mounted behind the robot, between the robotand the biochar production system 96, as shown. The modular biomassprocessing system 93 may also be mounted at the front of the robot. Thebiomass processing unit 93 may also be mounted at the front or back of amanually driven tractor. All components may be connected to a tractor inthe same manner as they are connected to the robot. The processingsystem may consist of an array of cutting tools whose pitch, speed andposition can be adjusted depending on the type, size, density andmoisture content of the incoming biomass, step 94. The biomass isprocessed to a predetermined size and consistency, and then conveyedusing air or a mechanical mechanism to the loading hopper, step 95. Thebiomass is further dried and preheated to a predetermined moistureconcentration and temperature using a combination of onboard heatingelements and hot exhaust gas from the biochar production system, step96. The mass, color, particle size and type of biomass is recorded usingan array of onboard sensors, step 97. An array of mechanical implementsattached to augers in the hopper are used to further process the biomassand load it into the biochar production system, step 98. The robot mayinclude a single or multiple biochar production systems and augersoperating in parallel, step 99. In some embodiments, multiple pyrolyzingaugers may be operated in parallel to increase capacity and throughput.Exhaust gases from the biochar production system are vented and/orflared using an exhaust vent, step 100. An Array of onboard sensorsmeasure and track the composition of the exhaust gas, step 101. Anonboard sprayer applies water and additives including chemical ororganic fertilizer to the produced biochar to reduce the temperature andapply nutrients or other soil amendments, step 102.

As shown in FIG. 17 , biomass is loaded into a hopper, step 103, whereit is weighed and characterized according to moisture content, color andtype. A combination of heating elements and exhaust gases from thebiochar reactor are used to further dry and preheat the biomass, step104. Biomass is loaded into the biochar reactor using anelectrically-driven or mechanically-driven auger, whose speed can becontrolled by the system's onboard computer, step 105. Biomass is driventhrough the reactor by the rotating auger, step 106. An array of sensorsare embedded into the walls of the reactor including temperature,cameras, moisture, humidity and gas concentration sensors, step 107. Thechamber and/or auger are heated using a resistance or induction heatingsource, and/or flame heat from burning fuel and exhaust gas, and/or alight source such as a laser emitter, step 108. The temperature of thereactor is controlled across its length by the system's onboardcomputer, which adjusts the temperature of the heating sources, step109. The reactor may be operated at atmospheric pressure, or may bepurged of oxygen by injecting an inert gas such as nitrogen or carbondioxide, step 110. The heated biochar is ejected from the system usingthe auger, step 111. A conductive material such as metal beads or shotmay be mixed with the incoming biomass and mechanically or magneticallyremoved from the biochar to improve heat transfer within the auger, step112.

As shown in FIG. 18 , biomass is loaded into a hopper, step 113, whereit is weighed and characterized according to moisture content, color andtype. A combination of heating elements and exhaust gases from thebiochar reactor are used to further dry and preheat the biomass, step114. Biomass is loaded into the biochar reactor using anelectrically-driven or mechanically-driven auger, whose speed can becontrolled by the system's onboard computer, step 115. Biomass is driventhrough the reactor by the rotating auger, step 116. An array of sensorsare embedded into the walls of the reactor including temperature,cameras, moisture, humidity and gas concentration sensors, step 117. Thechamber and/or auger are heated using a resistance or induction heatingsource, and/or flame heat from burning fuel and exhaust gas, and/or alight source such as a laser emitter, step 118. In the case ofinduction, the induction coils are wrapped around the length of thereactor, which may be covered in insulating material such as refractoryor mineral wool, step 119. The temperature of the reactor is controlledacross its length by the system's onboard computer, which adjusts thetemperature of the heating sources, step 120. The reactor may beoperated at atmospheric pressure, or may be purged of oxygen byinjecting an inert gas such as nitrogen or carbon dioxide, step 121. Theheated biochar is ejected from the system using the auger, step 122. Aconductive material such as metal beads or shot may be mixed with theincoming biomass and mechanically or magnetically removed from thebiochar to improve heat transfer within the auger, step 123.

As shown in FIG. 19 , the biochar production system can operate as astandalone, stationary and/or mobile system, step 124. Biomass is loadedinto a hopper, step 125, where it is weighed and characterized accordingto moisture content, color and type. A combination of heating elementsand exhaust gases from the biochar reactor are used to further dry andpreheat the biomass, step 126. Biomass is loaded into the biocharreactor using an electrically-driven or mechanically-driven auger, whosespeed can be controlled by the system's onboard computer, step 127.Biomass is driven through the reactor by the rotating auger powered byan electric power supply, or mechanical drive, step 128, at a ratedetermined by the system's onboard computer and data from sensors. Anarray of sensors are embedded into the walls of the reactor includingtemperature, cameras, moisture, humidity and gas concentration sensors,step 129. The chamber and/or auger are heated using a resistance orinduction heating source, and/or flame heat from burning fuel andexhaust gas, and/or a light source such as a laser emitter, step 130. Inthe case of induction, the induction coils are wrapped around the lengthof the reactor, which may be covered in insulating material such asrefractory or mineral wool, step 131. In the case of induction, aninduction furnace and power supply are used to charge the induction coiland circulate cooling water, step 132. The temperature of the reactor iscontrolled across its length by the system's onboard computer, whichadjusts the temperature and power of the heating sources, step 133. Thereactor may be operated at atmospheric pressure, or may be purged ofoxygen by injecting an inert gas such as nitrogen or carbon dioxide,step 134. The heated biochar is ejected from the system using the auger,step 135. A conductive material such as metal beads or shot may be mixedwith the incoming biomass and mechanically or magnetically removed fromthe biochar to improve heat transfer within the auger, step 136. Anexhaust system generates negative air pressure to capture and safelyvent or flare any emissions or exhaust gases generated by the system,step 137.

FIG. 20 is an example of a stationary biochar production system 210 andpyrolysis reactor 213 heated by induction heating elements, similar tothat of FIG. 19 . The stationary biochar production system may comprisea hopper 211 to hold biomass feedstock to be fed into the pyrolysisreactor. An auger driving motor 212 may be used to turn a pyrolyticauger. The pyrolytic auger may transport biomass feedstock from thehopper 211 into the pyrolysis reactor 213 to pyrolyze and/or combust thebiomass feedstock. The biochar generated in the pyrolysis reactor 213may be further carried by the pyrolytic auger or a quenching auger to abiochar handling system 214. The biochar handling system 214 may beconfigured to feed the biochar into a storage container or onto aconveyance system to store or apply the biochar at a different location.

FIG. 21A illustrates an example of the biochar production system andpyrolysis system 220 in accordance with aspects of the presentdisclosure. The pyrolysis system 220 may comprise one or more thermallyinsulated enclosures 221, one or more auger drive motors 225, one ormore gear reducers 226, a hopper 227, an exhaust system, one or morecooling and quenching systems 233 and one or more biochar handlingsystems 235.

The thermally insulated enclosure 221 may comprise one or more augershafts 222, one or more cut flights 223, one or more standard flights224 and induction heating zone 228.

The cut flights 223 and/or the standard flights 224 may be of fixed orvariable pitch. The cut flights 223 may be comprise one or more cuts tothe flight and/or comprise cut and folded flights. The cut flights 223may further process biomass by cutting the biomass while pushing thebiomass into the thermally insulated enclosure. Once in the thermallyinsulated enclosure, standard flights carry the biomass into theinduction heating zone 228 for pyrolyzation. Induction coils may bewrapped around the induction heating zone to create a pyrolytic reactorsection of the thermally insulated enclosure. The induction heating zone228 may induce heating of the thermally insulated enclosure, the augershaft 222, the auger standard flights 224 and any metallic conductivematerial added to the biomass to induce additional heat from within thebiomass itself. The addition of conductive material, such as metallicshot, may provide an even heating of the biomass material. Additional oralternative heating sources may be used to drive the pyrolyzation ofbiomass in the pyrolytic reactor section. Within the pyrolytic reactorsection, both pyrolysis reaction may occur simultaneously withcombustion reactions. The balance between the pyrolytic reactions andthe combustion reactions may be controlled by adjusting the parametersinside the pyrolytic reactor. Injection of exhaust gas, inert gas,atmospheric gas or steam may be used to control the amount of pyrolysisand combustion occurring at any time in the pyrolytic reactor. Theinjection of atmospheric gas into the chamber may increase the amount ofcombustion occurring in the pyrolytic reactor. Injection of exhaust gasor inert gas may decrease or eliminate combustion in the reactor.Injection of steam may be used to drive a gasification reaction in thereactor to generate syngas or other desirable and/or combustiblebyproducts.

The flight configuration may determine material flow and ability tomitigate feedstock bridging. The auger flights 223 and 224 may beinterchangeable with flights better suited for the biomass beingprocessed.

The auger drive motor 225 may be coupled to the one or more auger shafts222 by one or more gear reducers 226. The rate of turning of the augershaft 222 may be varied based on speed of travel of the tractor pullingthe pyrolysis system 220, the desired residence time, or characteristicsof the biomass feedstock being collected and fed into the hopper 227.Biomass with a higher moisture content may require a slower turning rateto compensate for the added moisture in the pyrolysis reactor.

The exhaust system may comprise enclosure/exhaust coupler 229, acatalytic combustor 230, a chimney stack 231 and an up-draft assist 232.The exhaust gases produced by the pyrolyzation of biomass in thepyrolytic reactor may be directed through an enclosure/exhaust coupler229 and into a catalytic combustor 230. The catalytic combustor 230 maybe used to lower the combustion temperature of the smoke and vapor inthe exhaust gases, allowing for a complete combustion of non-pyrolyzedmaterial that are given off as exhaust. The chimney stack 231 andup-draft assist 232 may provide channel the exhaust gas out of thepyrolytic reactor for further processing or venting into the atmosphere.Combusted and/or uncombusted exhaust gasses may be redirected from thechimney stack 231 back into the pyrolytic reactor. The up-draft assist232 may include a flare component to burn any remaining unburned smokebefore it leaves the system.

Cooling and quenching system 233 may comprise a cooling auger 234,active and passive cooling components, a nutrient integrator and one ormore biochar sensor arrays. Active cooling may be accomplished byspraying water, applying fire retardant or using a blower to reduce thetemperature of the biochar. Passive cooling may be accomplished by usingheat sinks, peltier coolers or refrigeration units to reduce thetemperature of the biochar.

The sensor arrays in the cooling and quenching system 233 may be used todetermine, characterize and monitor the composition of the biochar.Based on the determined composition, the nutrient integrator may infusenutrients and/or soil amendments directly into the biochar. The biocharmay be infused with fertilizer, compost, compost tea, nitrogen,pesticide, fungicide, herbicide, bacteria, yeast, fungi and otheradditives. In some embodiments, the biochar may also be mixed withnon-pyrolyzed crop residue before being applied to the soil or stored.The nutrient integrator may also integrate fluids with the biochar forcooling. Fluids may comprise Nitrogen, Phosphorous, Potassium, Calcium,Magnesium, Sulfur, Iron, Manganese, Copper, Zinc, Boron, Molybdenum,other derivatives to facilitate plant growth and/or balance soil pH orcombination thereof.

The pyrolysis reactor may be optimized by adjusting parameters based onthe monitoring of the biochar composition, exhaust gas composition andbiomass composition. To optimize the pyrolysis reactions in the reactor,adjustments may be made to the temperature of the heat source, oxygenconcentration in the pyrolysis reactor, the intensity of the blower orinert gas source and residence time. Residence time may be decreased byincreasing speed of travel of the pyrolytic auger and/or tractor pullingthe pyrolytic system.

After the biochar is cooled, quenched and/or infused with nutrients, thecooling and quenching auger 234 may carry the processed biochar into thebiochar handling system 235. The biochar handling system 235 mayconfigured to control the application of biochar back into the soil, thedepositing of biochar into a storage receptacle and the tracking andmapping of the amount of biochar being reintegrated back into the soil.

FIGS. 21B-D illustrate examples of pyrolytic augers in accordance withaspects of the present disclosure. FIG. 21B shows an example pyrolyticauger configured with a section of cut flights 223, which may be at astandard spacing. The cut flights 223 then transition to standardflights 224 for the remainder of the shafts length. FIG. 21C shows anexample pyrolytic auger configured with cut and folded flights 223A,which may be at a standard spacing. The cut and folded flights 223A maytransition to a standard flight 224A, wherein the transition occurs overa predetermined length, and wherein the transition narrow the flightspacing from the standard spacing to one which is narrower than thestandard spacing. In some embodiments, the spacing may be narrowed at aconstant or variable rate over the entire length of the auger shaft. Inother embodiments, the narrowing is restricted to a transition region,with the remainder of the flights having the same but smaller flightspacing 224B. In some embodiments, the transition may be from a standardflight spacing to a spacing that is between ¼ and ½ narrower. In otherembodiments the narrowing of the flights may be by ⅓. FIG. 21D shows anexample pyrolytic auger configured with a flight transition portion 224Cof the pyrolytic auger, wherein the flight transition portion 224Ctransitions the flights from a standard spacing to a double flightspacing 224D.

FIGS. 21E and 21F illustrate an example of a pyrolytic auger with ahollow shaft in accordance with aspects of the present disclosure. Thepyrolytic auger shaft 222 of FIG. 21A may be replaced or used inconjunction with the hollow pyrolytic auger shaft 236 of FIGS. 21E and21F. The hollow pyrolytic auger shaft 236 may comprise a plurality ofinjection holes 237. Exhaust gas, inert gas, atmospheric gas, steam orcombination thereof may be injected into the pyrolytic reactor area ofthe system to adjust properties and characteristics of the pyrolysisreaction, the produced biochar and the exhaust gases generated. FIG. 21Fshows a bisected view of the hollow pyrolytic auger shaft 236.

FIGS. 22A-22F illustrates an example of a towable biochar productionsystem and pyrolysis reactor in accordance with aspects of the presentdisclosure. The trailer based biochar system 240 may comprise a trailerhitch 241 and a trailer bed 242. Mounted onto the trailer bed 240 may bea biomass intake 243, pyrolytic auger encasement 244, exhaust andbiochar transfer unit 245, quenching auger assembly 246, biocharhandling system 247, collection receptacle mount 248, biochar collectionreceptacle 249, water tank 250, hopper 251 and liquid nutrient tanks253.

The hopper 251 may receive preprocessed biomass from a forage harvesteror other harvesting unit. In some embodiments, the hopper 251 may beconfigured to determine the moisture content of the biomass, and basedon the determination, perform a drying operation on the biomass if themoisture level is above a predetermined threshold. The hopper 251 maydirect the biomass into a biomass intake 243. The biomass intake 243feeds the dried biomass into the pyrolytic auger encasement 244. Apyrolytic auger is rotated to transfer the biomass into a pyrolyticreaction region within the encasement. After the pyrolysis reaction hasbeen completed in the encasement, the exhaust and biochar transfer unit245 may direct the generated exhaust gas into the atmosphere directly orthrough a chimney with a catalytic combustor. The transfer unit 245 maythen also transfer the hot biochar into a quenching auger assembly 246to reduce the temperature of the biochar. Within the quenching augerassembly 246, water and liquid nutrients from water tank 250 and liquidnutrient tanks 253 may be integrated into the biochar to reduce thetemperature of the biochar at the same time as applying nutrients andsoil amendments.

The biochar handling system 247 may be configured to distribute andintegrate the receive postprocessed biochar into the soil or it may beconfigured to transfer it into a collection receptacle 249. Thecollection receptacle may be mounted to the trailer by a collectionreceptacle mount 248.

FIGS. 22G-22H illustrate a thermally insulated enclosure of a pyrolyticauger, a cooling system of a quenching auger and the connecting of thetwo structures in accordance with aspects of the present disclosure.

The connection of the two components is accomplished through by way of apyrolysis enclosure coupler 252A and a cooling system coupler 252B. Thecoupling allows the exhaust and biochar transfer unit 245 to directlytransfer the biochar into the quenching auger assembly 246 forpostprocessing of the biochar.

FIG. 22I illustrates an example of a biochar production system andpyrolysis reactor being towed by a tractor with an attached frontalforage harvester in accordance with aspects of the present disclosure.The biochar system of FIG. 22I is similar to that of FIGS. 22A-22F.However, in FIG. 22I, the biochar system 240 is shown as being attachedto a mobile platform 255. The mobile platform may be autonomous,semi-autonomous and human supervised or human operated tractor. Themobile platform may be any tractor or vehicle capable of hauling thebiochar trailer. The mobile platform may be attached to the trailer attrailer hitch 241.

A forage harvester 256 may be mounted to the front of the mobileplatform 255. The forage harvester 256 may also be mounted at otherpositions on the mobile platform 255. Front mounted sensor array 257 maybe configured to analyze the biomass in front of the harvester. Thefront mounted sensor array 257 may be mounted directly on the forageharvester 256 or onto the mobile platform 255.

The biomass conveyor system 258 may receive preprocessed biomass fromthe forage harvester 256. The conveyor system may further preprocess thebiomass as it transfers the biomass from the forage harvester 256 to thehopper 251. In some embodiments, the further processing in the conveyorsystem 258 may comprise further cutting, chopping or milling of thebiomass. The further processing may also include heating and drying ofthe biomass during the transfer of the biomass, reducing the amount ofadditional processing needed at the hopper 251 and the biomass intake243. The conveyor system may use a conveyor belt, auger, forced air,suction or combination thereof to perform the transferring of thebiomass into the auger.

The biomass transfer unit 259 may directly couple the conveyor system258 to the hopper 251. In some embodiments, one or more additional unitsmay be positioned between the transfer unit 259 and the conveyor system258 as well as between the transfer unit 259 and the hopper 251. In someembodiments, the transfer unit 259 may make the transfer of biomass inopen air, such as by dropping the biomass into a hopper while beingseparated from the hopper by open air.

Biochar spreading attachment 260, may comprise one or more sensor arraysto measure the quality, composition and mass of the biochar beinghandled. The sensor may also analyze the application density of thebiochar. The biochar spreading attachment 260 may also comprisecomponents configured to produce an even application of biochar to thesoil. The spreading attachment 260 may work in conjunction with thebiochar plowing attachment 261 to evenly distribute and integrate thebiochar into the soil.

The biochar plowing attachment 261, comprise plowshares, moldboards andcoulters. The plowing attachment 261 may adjust the depth and spacing ofthe component based on the distribution pattern, density and rate of thespreading attachment 260. Other raking and tilling implements may alsobe attached to the mobile platform 255 and/or the trailer itself. Thebiochar spreading attachment 260 and the biochar plowing attachment 261may be replaced or substituted by these other raking and tillingimplements, or may be removed, uninstalled or not installed in the firstplace.

FIG. 23 illustrates an example of a Mobile Biochar Generation System(MBGS) 300 in accordance with aspects of the present disclosure. Mobilebiochar generation system 300 may comprise an MBGS controller 305,pyrolysis system 310, power source 315, sensor array 320, pretreatmentsystem 325 and cooling system 330.

The MBGS Controller 305 may coordinate the operation of the pyrolysissystem 310, pretreatment system 325 and cooling system 330 based on theinformation received from sensor array 320. The MBGS controller 305 mayalso control navigation of a tractor integrated with the system tofacilitate maneuvering of the system over a field. The MBGS controller305 may also be configured to control harvesting equipment and equipmentfor the distribution and integration of the biochar into the soil of thefield.

Power source 315 may be used in the operation of the controller 305, aswell as that of the pyrolysis system 310, pretreatment system 325 andcooling system 330. The power source 315 may battery or generator based.

The MBGS 300 may communicate with client 350, server 360 and datastore365 over network 340. Client device 350 may be a personal computer,handheld computing device, smartphone or other user operated devicesthat can communicate with the MBGS 300, either directly or over network340. Server 360 may be any computing device(s) capable of performing themethods and processes described in this disclosure. Datastore 365 maystore data generated from the MBGS, including readings from sensorarrays, analytical results of the biomass, biochar, exhaust gas or anyother raw or processed information produced as a result of the operationof the system.

FIG. 24A illustrates an example of MBGS controller in accordance withaspects of the present disclosure. The MBGS controller 305 may comprisea pyrolysis system control module 400, pretreatment system controlmodule 405, cooling system control module 410, sensor analysis module415, power module 420, and a communication module 425.

Pyrolysis system control module 400 may control all aspects of thepyrolytic reactor and pyrolytic auger. The controller may be configuredto adjust gas injection, temperature and residence time within thepyrolytic reactor. Pretreatment system control module 405 may be used tocontrol the harvesting, chopping, conveyance and drying of the biomass.The cooling system control module 410 may control the operation ofblowers, water sprayers, peltier coolers, refrigeration units andnutrient integration into the biochar. The sensor analysis module 415may be configured to determine composition and other characteristics ofthe biomass before harvesting, during harvesting, during preprocessingand during pyrolysis. The sensor analysis module 415 may also beconfigured to determine composition and other characteristics of thebiochar and exhaust gas during pyrolysis, after pyrolysis, duringquenching and cooling, after nutrient infusion, and after distributionand integration of the biochar into the soil.

Communication module 425 may comprise a LoRa module 430, BLE module 435,3GPP module 440 and WIFI module 445.

FIG. 24B illustrates an example of a sensor array 320 in accordance withaspects of the present disclosure. Sensor array 320 may comprise asensor controller 450, a temperature sensor module 455, a humiditysensor module 460, biomass sensor module 465, a biochar sensor module470, a pyrolysis sensor module 475, an exhaust sensor module 480, anavigation sensor module 485, a flame sensor module 490 and a visionsensor module 495.

Although specific features of the invention are shown in some drawingsand not in others, this is for convenience only as each feature may becombined with any or all of the other features in accordance with theinvention. The words “including”, “comprising”, “having”, and “with” asused herein are to be interpreted broadly and comprehensively and arenot limited to any physical interconnection. Moreover, any embodimentsdisclosed in the subject application are not to be taken as the onlypossible embodiments. Other embodiments will occur to those skilled inthe art and are within the following claims.

In addition, any amendment presented during the prosecution of thepatent application for this patent is not a disclaimer of any claimelement presented in the application as filed: those skilled in the artcannot reasonably be expected to draft a claim that would literallyencompass all possible equivalents, many equivalents will beunforeseeable at the time of the amendment and are beyond a fairinterpretation of what is to be surrendered (if anything), the rationaleunderlying the amendment may bear no more than a tangential relation tomany equivalents, and/or there are many other reasons the applicantcannot be expected to describe certain insubstantial substitutes for anyclaim element amended.

FIG. 25 illustrates an example machine of a computer system within whicha set of instructions, for causing the machine to perform any one ormore of the methodologies discussed herein, may be executed. Inalternative implementations, the machine may be connected (e.g.,networked) to other machines in a LAN, an intranet, an extranet, and/orthe Internet. The machine may operate in the capacity of a server or aclient machine in client-server network environment, as a peer machinein a peer-to-peer (or distributed) network environment, or as a serveror a client machine in a cloud computing infrastructure or environment.

The machine may be a personal computer (PC), a tablet PC, a set-top box(STB), a Personal Digital Assistant (PDA), a cellular telephone, a webappliance, a server, a network router, a switch or bridge, or anymachine capable of executing a set of instructions (sequential orotherwise) that specify actions to be taken by that machine. Further,while a single machine is illustrated, the term “machine” shall also betaken to include any collection of machines that individually or jointlyexecute a set (or multiple sets) of instructions to perform any one ormore of the methodologies discussed herein.

The example computer system 2500 includes a processing device 2502, amain memory 2504 (e.g., read-only memory (ROM), flash memory, dynamicrandom access memory (DRAM) such as synchronous DRAM (SDRAM) or RambusDRAM (RDRAM), etc.), a static memory 2506 (e.g., flash memory, staticrandom access memory (SRAM), etc.), and a data storage device 2518,which communicate with each other via a bus 2530.

Processing device 2502 represents one or more general-purpose processingdevices such as a microprocessor, a central processing unit, or thelike. More particularly, the processing device may be complexinstruction set computing (CISC) microprocessor, reduced instruction setcomputing (RISC) microprocessor, very long instruction word (VLIW)microprocessor, or processor implementing other instruction sets, orprocessors implementing a combination of instruction sets. Processingdevice 2502 may also be one or more special-purpose processing devicessuch as an application specific integrated circuit (ASIC), a fieldprogrammable gate array (FPGA), a digital signal processor (DSP),network processor, or the like. The processing device 2502 is configuredto execute instructions 2526 for performing the operations and stepsdiscussed herein.

The computer system 2500 may further include a network interface device2508 to communicate over the network 2520. The computer system 2500 alsomay include a video display unit 2510 (e.g., a liquid crystal display(LCD) or a cathode ray tube (CRT)), an alphanumeric input device 2512(e.g., a keyboard), a cursor control device 2514 (e.g., a mouse), agraphics processing unit 2522, a signal generation device 2516 (e.g., aspeaker), graphics processing unit 2522, video processing unit 2528, andaudio processing unit 2532.

The data storage device 2518 may include a machine-readable storagemedium 2524 (also known as a computer-readable medium) on which isstored one or more sets of instructions or software 2526 embodying anyone or more of the methodologies or functions described herein. Theinstructions 2526 may also reside, completely or at least partially,within the main memory 2504 and/or within the processing device 2502during execution thereof by the computer system 2500, the main memory2504 and the processing device 2502 also constituting machine-readablestorage media.

In one implementation, the instructions 2526 include instructions toimplement functionality corresponding to the components of a device toperform the disclosure herein. While the machine-readable storage medium2524 is shown in an example implementation to be a single medium, theterm “machine-readable storage medium” should be taken to include asingle medium or multiple media (e.g., a centralized or distributeddatabase, and/or associated caches and servers) that store the one ormore sets of instructions. The term “machine-readable storage medium”shall also be taken to include any medium that is capable of storing orencoding a set of instructions for execution by the machine and thatcause the machine to perform any one or more of the methodologies of thepresent disclosure. The term “machine-readable storage medium” shallaccordingly be taken to include, but not be limited to, solid-statememories, optical media and magnetic media.

FIG. 26A is a flow chart illustrating the operation of the mobilebiochar generation unit 2600 in accordance with some embodiments.

At step 2601, the system may control, by a system controller, a mobilebiochar generation system. At step 2602, the system may determine anoptimal path for the mobile biochar generation system to traverse. Atstep 2603, the system may operate a harvesting unit to collect andharvest biomass feedstock to be pyrolyzed. At step 2604, the system maymonitor, using a first sensor array, the harvested biomass feedstock. Atstep 2605, the system may load, by a pyrolyzing auger, the harvestedbiomass feedstock into a pyrolytic reactor. At step 2606, the system maypyrolyze, in the pyrolytic reactor, the harvested biomass feedstock togenerate biochar and exhaust gas. At step 2607, the system may monitor,using the second sensor array, the biochar and the exhaust gas. At step2608, the system may postprocess the biochar based on the monitoring ofthe feedstock, the biochar and exhaust gas. At step 2609, the system maydetermine optimization adjustments of one or more operating parametersof the pyrolytic reactor based on the monitoring of the biochar andexhaust gas. At step 2610, the system may make adjustments of the one ormore operating parameters of the pyrolytic reactor based on thedetermined optimization adjustments. The system may then continue topyrolyze the harvested biomass feedstock with the adjusted operatingparameters.

FIG. 26B is a flow chart illustrating the postprocessing of biochar 2608in the mobile biochar generation unit in accordance with someembodiments.

At step 2611, the system may determine the composition of the biocharand exhaust gas. At step 2612, the system may cool, in a cooling andquenching auger assembly, the biochar to a predetermined temperature. Atstep 213, the system may infuse the biochar with nutrients or soilamendments. At step 2614, the system may handle, by a biochar handlingunit, the infused biochar, wherein the handling comprises application ofthe infused biochar into a soil region. At step 2615, the system maymonitor, by a third sensor array, the infused biochar and determine thecomposition and mass of the infused biochar. At step 2616, the systemmay map the application of the infused biochar to a correspondingcoordinate system of a piece of land. At step 2617, the system may storethe mapping of the infused biochar application.

Some portions of the preceding detailed descriptions have been presentedin terms of algorithms and symbolic representations of operations ondata bits within a computer memory. These algorithmic descriptions andrepresentations are the ways used by those skilled in the dataprocessing arts to most effectively convey the substance of their workto others skilled in the art. An algorithm is here, and generally,conceived to be a self-consistent sequence of operations leading to adesired result. The operations are those requiring physicalmanipulations of physical quantities. Usually, though not necessarily,these quantities take the form of electrical or magnetic signals capableof being stored, combined, compared, and otherwise manipulated. It hasproven convenient at times, principally for reasons of common usage, torefer to these signals as bits, values, elements, symbols, characters,terms, numbers, or the like.

It should be borne in mind, however, that all of these and similar termsare to be associated with the appropriate physical quantities and aremerely convenient labels applied to these quantities. Unlessspecifically stated otherwise as apparent from the above discussion, itis appreciated that throughout the description, discussions utilizingterms such as “identifying” or “determining” or “executing” or“performing” or “collecting” or “creating” or “sending” or the like,refer to the action and processes of a computer system, or similarelectronic computing device, that manipulates and transforms datarepresented as physical (electronic) quantities within the computersystem's registers and memories into other data similarly represented asphysical quantities within the computer system memories or registers orother such information storage devices.

The present disclosure also relates to an apparatus for performing theoperations herein. This apparatus may be specially constructed for theintended purposes, or it may comprise a general purpose computerselectively activated or reconfigured by a computer program stored inthe computer. Such a computer program may be stored in a computerreadable storage medium, such as, but not limited to, any type of diskincluding floppy disks, optical disks, CD-ROMs, and magnetic-opticaldisks, read-only memories (ROMs), random access memories (RAMs), EPROMs,EEPROMs, magnetic or optical cards, or any type of media suitable forstoring electronic instructions, each coupled to a computer system bus.

Various general purpose systems may be used with programs in accordancewith the teachings herein, or it may prove convenient to construct amore specialized apparatus to perform the method. The structure for avariety of these systems will appear as set forth in the descriptionabove. In addition, the present disclosure is not described withreference to any particular programming language. It will be appreciatedthat a variety of programming languages may be used to implement theteachings of the disclosure as described herein.

The present disclosure may be provided as a computer program product, orsoftware, that may include a machine-readable medium having storedthereon instructions, which may be used to program a computer system (orother electronic devices) to perform a process according to the presentdisclosure. A machine-readable medium includes any mechanism for storinginformation in a form readable by a machine (e.g., a computer). Forexample, a machine-readable (e.g., computer-readable) medium includes amachine (e.g., a computer) readable storage medium such as a read onlymemory (“ROM”), random access memory (“RAM”), magnetic disk storagemedia, optical storage media, flash memory devices, etc.

In the foregoing disclosure, implementations of the disclosure have beendescribed with reference to specific example implementations thereof. Itwill be evident that various modifications may be made thereto withoutdeparting from the broader spirit and scope of implementations of thedisclosure as set forth in the following claims. The disclosure anddrawings are, accordingly, to be regarded in an illustrative senserather than a restrictive sense.

1. An apparatus for in-field production of biomass into biochar, theapparatus comprising: a mobile biochar generation system, wherein themobile biochar generation system comprises: a mobile platform, whereinthe mobile platform comprises a tractor unit; a trailer unit, whereinthe trailer unit comprises a trailer bed and a trailer hitch, whereinthe trailer hitch connects the mobile platform with the trailer unit; aharvesting unit, wherein the harvesting unit comprises: a first sensorarray, configured to monitor the biomass being harvested; a forageharvester, wherein the forage harvester is mounted to the front of themobile platform; a biomass intake unit, wherein the biomass intake unittransfers the harvested biomass to a conveyor unit; wherein the conveyerunit transfers the harvested biomass to from the forage harvester to abiomass transfer unit; and wherein the biomass transfer unit depositsthe harvested biomass to a pyrolytic system; the pyrolytic systemcomprising: a biomass intake unit, wherein the biomass intake unitcomprises a hopper unit, wherein the biomass intake unit receivesharvested biomass into the hopper unit; a pyrolytic reactor unit,wherein the pyrolytic reactor unit comprises: a pyrolysis control unit,wherein the pyrolysis control unit controls temperature and gasinjection; a pyrolytic auger, wherein the pyrolytic reactor comprises: afirst portion with one or more cut flights; and a second portionconfigured to transition from a first flight spacing to a second flightspacing; a thermally insulated reactor enclosure; an exhaust transferunit; a biochar transfer unit; a heating unit; and a second sensorarray; an exhaust handling unit, wherein the exhaust handling unitcomprises: an exhaust coupling unit; a chimney unit; a blower unit; anda catalytic combustor; a cooling unit, wherein the cooling unitcomprises: a quenching auger assembly, wherein the quenching augerassembly further comprises: one or more active cooling components,wherein the active cooling components comprise blowers and watersprinklers; and one or more passive cooling components, wherein thepassive cooling components comprise heat sinks, peltier coolers andrefrigeration units; one or more water storage units; one or morenutrient storage units; and a nutrient integration unit; a biocharhandling system, wherein the biochar handling system comprises: abiochar spreading unit; a biochar plowing unit; and a third sensorarray.
 2. The apparatus of claim 1, wherein the pyrolysis control unitoptimizes pyrolyzing in the pyrolytic reactor by adjusting one or moreoperating parameters of the pyrolytic reactor, wherein the one or moreoperating parameters are determined based on a determined composition ofbiochar and exhaust gas.
 3. The apparatus of claim 1, wherein thepyrolytic reactor unit generates biochar and exhaust gas from theharvested biomass.
 4. The apparatus of claim 3, wherein the nutrientintegration unit infuses the biochar with nutrients or soil amendmentsto produce infused biochar.
 5. The apparatus of claim 4, wherein thebiochar handling system integrates the infused biochar into a soilregion.
 6. The apparatus of claim 5, wherein the biochar handling systemmaps the amount of the infused biochar integrated into the soil to acorresponding coordinate system of a piece of land.
 7. A biocharproduction system, the system comprising: a mobile platform configuredto drive across open land containing biomass feedstock; a trailercoupled to and configured to be moved by the mobile platform; aharvesting unit coupled to the mobile platform, wherein the harvestingunit is configured to harvest biomass feedstock from the open land; anda pyrolytic unit located on the trailer, wherein the pyrolytic unit isconfigured to receive biomass feedstock harvested by the harvesting unitand convert via pyrolysis the harvested biomass feedstock into biocharand exhaust gas.
 8. The system of claim 7, wherein the mobile platformincludes a tractor.
 9. The system of claim 7, wherein the mobileplatform is autonomous.
 10. The system of claim 9, wherein the mobileplatform includes one or more sensors and one or more processors, andwherein the mobile platform is configured to determine automatically anoptimal path for the mobile platform to drive across the open land. 11.The system of claim 7, wherein the pyrolytic unit is configured todetermine a composition of biochar and exhaust gas produced in thepyrolytic unit.
 12. The system of claim 11, wherein the pyrolytic unitis further configured to optimize the pyrolysis performed therein byadjusting one or more operating parameters based on the determinedcomposition of biochar and exhaust gas.
 13. The system of claim 7,wherein the harvesting unit includes a forage harvester located in frontof or behind the mobile platform.
 14. The system of claim 7, furthercomprising: a nutrient integration unit, wherein the nutrientintegration unit is configured to infuse the biochar with nutrients orsoil amendments to produce infused biochar.
 15. The system of claim 14,further comprising: a biochar handling system configured to integratethe infused biochar into a soil region at or proximate the open land.16. The system of claim 15, wherein the biochar handling system includesa biochar spreading unit configured to control the amount and density ofthe infused biochar applied to the soil region and a biochar plowingunit configured to control integration of the infused biochar into thesoil region.
 17. The system of claim 15, wherein the biochar handlingsystem is further configured to map and store the amount of the infusedbiochar being integrated into the soil region to a correspondingcoordinate system.
 18. (canceled)
 19. The system of claim 14, whereinthe system is configured to monitor the harvested biomass feedstock totrack and characterize one or more characteristics or properties of theharvested biomass feedstock.
 20. The system of claim 7, wherein thesystem is configured to adjust one or more pyrolysis process parametersto produce a desired amount of one or more pyrolysis products.
 21. Thesystem of claim 20, wherein the one or more pyrolysis products includebiochar, pyrolysis gas, pyrolysis oil, or any combination thereof.